Non-Combustible, Net-Zero Energy Building Systems

This application is a continuation of U.S. application Ser. No. 18/544,014, filed on Dec. 18, 2023, which is a divisional of U.S. application Ser. No. 17/982,428 filed on Nov. 7, 2022, which claims the benefit of U.S. Provisional Application No. 63/344,757, filed on May 23, 2022, the contents of which are incorporated by reference herein.

The present disclosure generally relates to non-combustible building systems in the residential and commercial construction industry.

Problems with traditional building materials and processes arise relating to fire damage and energy efficiency in residential and commercial structures, both of which represent major concerns throughout the construction industry generally and in the state of California specifically. In addition to direct fire exposure, heat of combustion at 600 degrees Fahrenheit can cause building structures to ignite, and because traditional wood materials are highly flammable and combustible, these materials generally provide little protection to prevent a structure from burning.

No current solutions have completely addressed these problems. Some attempted solutions include simple mitigation tactics such as thickened stucco, closing off vents, and keeping brush away from homes, but these solutions focus on mitigation of direct fire exposure rather than fire and combustion resistance and prevention. Other solutions have attempted to use concrete rather than lumber for building walls, but concrete is a heavy material and susceptible to cracking. Some concrete solutions attempt to place an insulation layer between thick layers of concrete, but these thick concrete layers generally require steel reinforcements, which makes the concrete even heavier and more expensive. A need exists for a lightweight, cost-efficient solution that provides fire and combustion resistance and energy efficiency to residential and commercial building structures.

The present disclosure describes an insulated concrete wall panel for residential and commercial structures. The systems described herein may be used for preventing structural fire and combustion damage and, additionally, for providing energy-efficient and net-zero energy results to residential and commercial buildings.

Embodiments of the present disclosure present a sandwich wall panel with an insulation layer between two layers of concrete. Unlike prior sandwich wall configurations that use steel-reinforced concrete for the outer layers, the present disclosure describes the use of fiber-reinforced concrete, which is lighter, stronger, and more fire resistant. It is known throughout the construction industry that concrete has high strength under compression but relatively low strength undertension.

Large masses of concrete (such as concrete slabs, foundations, or wall panels) often require reinforcements to help the concrete maintain its form, especially when exposed to tension. Traditionally, steel cages have been used to reinforce concrete, but the steel reinforcements add weight to the concrete and require thickening of the concrete to protect the steel against rust and corrosion. Conversely, the present disclosure describes mixing fibrous materials (e.g., glass fibers, polypropylene, nylon) with concrete to produce a fiber-reinforced concrete composite material. The addition of fibers interwoven and embedded within the concrete provides numerous benefits discussed below, including tensile strength, lighter weight, fire resistance, and energy efficiency.

In general, innovative aspects of the subject matter described in this specification can be embodied in a wall panel that includes: at least two fiber-reinforced concrete layers including concrete with interwoven fibrous materials; an insulation layer; and a connector. The insulation layer is sandwiched between the at least two fiber-reinforced concrete layers, and the connector extends through the insulation layer and concrete layers to create composite action between the insulation layer and the concrete layers. Other implementations of this aspect include corresponding systems, apparatus, and methods.

In another general aspect, innovative aspects of the subject matter described in this specification can be embodied in methods that include actions of: providing a preset mold having a length in a first lateral dimension and a width in a second lateral dimension; forming a first concrete layer by pouring a wet concrete mix containing fibrous material into the preset mold; while the concrete mix is still wet, installing an insulation layer and one or more connectors such that the insulation layer and connectors embed into the first concrete layer in the preset mold; forming a second concrete layer by pouring the concrete mix containing fibrous material over the insulation layer and the connectors in the preset mold; and allowing the first and second concrete layers to dry such to form a sandwich wall panel with composite action between the first and second concrete layers, the insulation layer, and the connectors. A length of the insulation layer is less than the width of the preset mold, a width of the insulation layer is less than the width of the present mold, or both.

In another general aspect, innovative aspects of the subject matter described in this specification can be embodied in a building system that includes: multiple wall panels, each wall panel including a first concrete layer and a second concrete layer, each including fiber-reinforced concrete including concrete embedded with interwoven fibrous materials; an insulation layer disposed between the first concrete layer and the second concrete layer; multiple connectors spaced throughout the wall panel, each connector extending from the first concrete panel through the insulation layer and into the second concrete panel; a lifting anchor embedded in a first region at an upper end of the wall panel at which the insulation layer is recessed, thereby forming a first area of solid fiber-reinforced concrete extending between the first and second concrete layers; and a second region at a lower end of the wall panel at which the insulation layer is recessed, thereby forming a second area of solid fiber-reinforced concrete extending between the first and second concrete layers, the second region sized to accept at least two tapcon anchors. A perimeter edge of the insulation layer is inset from respective perimeter edges of the first and second concrete layers and an entirety of the perimeter edge of the insulation layer is covered by a cap of fiber reinforced concrete.

In another general aspect, innovative aspects of the subject matter described in this specification can be embodied in methods that include actions of: forming a first sandwich wall panel from a first preset mold and a second sandwich wall panel from a second preset mold; and bolting the first sandwich wall panel to the second sandwich wall panel by drilling at least one large diameter tapcon anchor through the solid fiber-reinforced concrete sections of the first and second sandwich wall panels. Each of the first and second sandwich wall panels include: two fiber-reinforced concrete layers; an insulation layer between the two fiber-reinforced concrete layers; at least one connector extending through the insulation layer and concrete layers; and a solid fiber-reinforced concrete section.

These and other implementations can each optionally include one or more of the following features.

In some implementations, the fiber-reinforced concrete layers are no greater than approximately two inches thick.

In some implementations, the insulation layer is at least approximately four inches thick.

In some implementations, the fiber-reinforced concrete layers include polypropylene fibers, polyethylene fibers, or both.

In some implementations, the wall panel includes a solid concrete section covering the insulation layer. In some implementations, the solid concrete section includes fiber-reinforced concrete material. In some implementations, the solid concrete section includes at least one large diameter tapcon anchor.

In some implementations, the fibrous materials in the concrete layers are configured to form air pockets when exposed to heat.

In some implementations, the wall panel does not include reinforcing steel materials.

In some implementations, the wall panel includes a solid fiber-reinforced concrete section having noinsulation layer. In some implementations, the solid concrete section includes at least one large diameter tapcon anchor.

In some implementations, the preset mold includes an opening. In some implementations, the actions include forming a window or a door in the sandwich wall panel from the opening in the preset mold.

In some implementations, the actions include lifting the sandwich wall panel from the preset mold.

In some implementations, the sandwich wall panel includes a solid fiber-reinforced concrete section.

In some implementations, the actions include adding a fiber-reinforced concrete section over the insulation layer such that the solid concrete section fully covers the insulation layer.

In some implementations, the length of the insulation layer is two inches less than the length of the preset mold, the width of the insulation layer is two inches less than the width of the preset mold, or both.

In some implementations, the preset mold has a length in a first lateral dimension and a width in a second lateral dimension, and where a length of the insulation layer is less than the width of the preset mold, a width of the insulation layer is less than the width of the present mold, or both.

In some implementations, the first concrete layer does not include steel reinforcements that extend completely within a plane defined by the first concrete layer. The second concrete layer does not include steel reinforcements that extend completely within a plane of the second concrete layer.

In some implementations, at least one of the wall panels includes a conduit box embedded within the first concrete layer and conduit connected to the conduit box embedded within the first concrete layer.

In some implementations, the actions include: positioning a first set of wall panels at a first elevation; after positioning the first set of wall panels, installing a floor over the first set of wall panels; after installing the floor, lifting and positioning a second set of wall panels over the first set of wall panels at a second elevation higher than the first elevation; and after lifting and positioning the second set of wall panels, installing a roof over the second set of wall panels. The first set of wall panels includes the first sandwich wall panel and the second sandwich wall panel.

Particular implementations of the subject matter described in this specification can be implemented so as to realize one or more of the following advantages.

High-strength concrete is non-flammable and non-combustible, providing superior fire resistance over conventional wood materials. Further, high-mass concrete with an insulation core stores and releases thermal energy allowing for lower use of HVAC systems to maintain desired temperature, thus providing a more affordable net-zero energy result.

Embodiments of the present disclosure include unique building systems with fiber-reinforced, insulated concrete wall panels for fire and combustion protection and energy efficiency.

is a perspective cutaway view of one embodiment of a wall panel configurationaccording to the present disclosure. The embodiment shown includes an insulation layersandwiched between two concrete layerswith multiple connectorsspaced throughout the wall panel configuration. The connectorsjoin the wall layers by extending from the first concrete layer to the second concrete layer.is sectional end view of one embodiment of a wall panel configurationaccording to the present disclosure.

Some embodiments may include a structural composite wall panel configuration with multiple layers functioning as a single wall. Some sections of the wall panel configurationinclude an insulation layersandwiched between two concrete layerson either side, as shown in. In other sections, the wall panel may be solid concrete without an insulation layer. In some embodiments, the insulation layermay have a certain thickness (e.g., at least approximately four inches) and each concrete layermay have a certain thickness (e.g., approximately two inches or less), forming, for example, a 2″-4″-2″ wall panel configuration, as shown in. The sandwich wall panels may include connectorsthrough the layers that create composite action between the layers (e.g., binding the layers together so strongly that they act together structurally as a single unit). The combination of composite materials creates a composite mold effect, meaning that the combination of the composite connectorswith the interwoven composite reinforcing fibers work together structurally once a bonding agent (e.g., solid concrete) is applied. In some embodiments, the majority of the wall panel material is composite material (e.g., approximately 70% composite material and approximately 30% concrete). Note that while two layers of concrete are illustrated in, the insulation layermay be sandwiched between more than two layers of concrete and more than one insulation layer may be present.

The solid concretecan allow for sturdy sections of the wall panel for providing the structural inserts for lifting and attaching the panels during the assembly of a building. In some implementations, the “top”, e.g., area of a wall panel that will be highest after assembly, can include structural attachment points, e.g., a lifting anchor, recessed in the solid concreteregions of the wall panelthat do not include the insulating layer. The lifting anchor can be metal tabs with a loop at the edge of the wall panel with a hook cabling, facilitate the lifting of the wall panel. The “bottom”, e.g., the area of the wall panel that will be lowest after assembly, can have attachment anchors in the solid concrete. In some implementations, the attachment anchors ring clutches than can allow for a range in orientations of wall panels as they are lifted and assembled.

The presence of solid concretearound the perimeter of the wall panel can also prevent fire or water penetration to the insulation layeror interior of the assembled building. This solid concrete perimeter can improve the safety and stability of a home, for example, compared to homes with exposed insulation.

Standard concrete used in home construction generally has an ideal temperature range, given that concrete is prone to cracking at extreme temperatures, e.g., greater than 120° F. and less than 10° F., given its differing coefficients of expansion and contraction. The disclosed combination of composite material, e.g., the fiber-reinforced concrete, on the other hand, is less likely to crack under extreme conditions, such as fluctuating temperatures in extreme climates, large temperature differentials between the inside and outside of the building, and tensile or compressive stress and strain.

The presence of the composite connectorscan have beneficial effects for the structural stability of a building, such as transferring load in deflection and shear stress from one layer concrete to another layer concrete. For example, during an earthquake, the force on the building from the ground shaking can be transferred from one layer concrete to another, preventing one particular layer from surpassing a threshold force that causes damage. In some implementations, the composite connectorsare fiber-reinforced rebar.

also shows an optional solid concrete sectionon the top of the wall panel. The solid concrete sectioncan have a certain thickness (e.g., approximately two inches thick or less) and can run along the entire length of all panel edges where the insulation layerwould be exposed. The solid concrete sectionmay protect the insulation layerfrom combustion or direct fire exposure and seal the walls from water damage and moisture so that no water or moisture reach and damage the insulation layer. The solid concrete sectioncan be made from similar concrete mix discussed above containing fibrous material, which provides additional strength and prevention of thermal cracking.

In some embodiments, the concrete layersare made from a fiber-reinforced concrete composite material, which avoids the need to use heavier steel reinforcements. The fibers are interwoven into the concrete and can include, but are not limited to, polypropylene, polyethylene macro fibers, or a combination thereof. Additionally, the insulation layercan be, but is not limited to, a foam material such as extruded polystyrene.

Reinforcing the concrete allows the concrete layersto be thinner (e.g., approximately two inches) without losing shape and form, and reinforcing the concrete with fibrous material allows the concrete layersto be lighter-weight than steel-reinforced concrete layers. Despite being thinner and lighter weight, fiber-reinforced concrete is also stronger than steel-reinforced concrete. A lighter-weight wall panel provides numerous benefits during construction such as the ability to use smaller equipment, ship more product per square foot, provide safer working conditions, and lessen the reinforcement needs for the footing system (e.g., less material needed to reinforce a house against slippage in soft ground conditions). Moreover, providing thinner concrete layers allows for a thicker insulation layerwithin standard wall thickness parameters (e.g., four inches of insulation within a standard eight inch wall panel), which provides increased energy efficiency by preventing heat from transferring from one concrete layerto the other. More specifically, the concrete layersdo not have steel reinforcements (e.g., rebar) that extend within the plane defined by the concrete layerand which are completely embedded in the layer. However, as noted above, some embodiments may include composite connectorsmade of fiber-reinforced rebar that extend between panelsin a direction along the thickness of the panels in order to join two panels.

Fiber-reinforced concrete is stronger under tension than steel-reinforced concrete. Improved tensile strength provides benefits particularly during shipping and installation, for example, when lifting the panels and preventing the wall panels from bowing under pressure. Further, the reinforcing fibers in the composite concrete material create air pockets when exposed to heat and fire, which slows the thermal transfer through the wall panel and provides additional fire and combustion resistance. The fibers also help strengthen the adhesion between the concrete layers, insulation layers, and adjoining connectors, strengthening the composite action in the wall panel.

Lifting anchorscan lift wall panel configuration. In some implementations, lifting anchorscan connect to a portion of the concrete layersthrough a hairpin rebar. In some implementations, the lifting anchorscan lift weights as great as several tons, e.g., four tons. In some implementations, each panel may include one or more (e.g., two to four) lifting anchorsdepending on the weight off the panel, and the lifting anchors can be evenly spaced to keep the panel level. In some implementations, the lifting anchors can be approximately three feet across.

Further, fiber-reinforced concrete provides additional fire-resistance to the wall panel, where the reinforcing fibers create air pockets when exposed to heat and fire, which slows the thermal transfer through the wall.

show onsite molding and lifting processes for manufacturing wall panels according to the present disclosure. A preset mold (e.g., ‘Jig”) is shown that can be reused without the need for set-up before each use, which reduces the need for highly skilled onsite labor.

In the home construction industry, wall panels are generally custom-made, e.g., not made with preset molds. The disclosed preset molds can be repeatedly used in a modular fashion. For example, a particular preset mold could be used for any story of the house or for different floor layouts. The molds can be made from steel, concrete, composite, or a combination thereof. In some implementations, wall panels are formed by pouring fiber concrete mix, bolting steel together, or a combination of both. In some implementations, the preset molds can be formed by welding steel down.

As shown in, embodiments of the present disclosure also include onsite molding and lifting methods and processes for manufacturing the wall panels disclosed herein. These processes greatly reduce the need for skilled labor by using a preset mold (e.g., a ‘Jig”). These methods standardize the construction process and therefore standardize the wall panels for each respective building.

is a flow diagram of a processfor constructing a wall panel. For example, a building system() can perform the process.

The building systemcan provide a preset mold (). In some implementations, the preset mold includes an opening. In some implementations, the preset mold rests on a substantially level plane.

The building systemcan form a first concrete layer. For example, a concrete layer can be formed by pouring a concrete mix, e.g., concrete mix, containing fibrous material into the preset mold, e.g., preset mold, as can be seen in(). In some implementations, the concrete mix, being a fluid, flows to fill the total area within the preset mold. Consequently, it can have the same lateral dimensions as the preset mold, e.g., the same height and width in a rectangular preset mold.

In some implementations, the final wall panel will include electrical wiring or sleeves for plumbing. For example, a standard conduit box with one or two outlets can be embedded in the first layer concrete, and conduits, e.g., wires 0.5-0.75 inches in width, can vertically run through the wall panel, such that the conduits of a first and a second wall panel would align in an assembled building. In some implementations, electrical wiring in the wall panel is realized by placing a spacer in the preset mold before pouring the concrete mix. The spacer provides a cavity for standard conduit box. The junction boxes can be added flesh to the surface of the wall panel. In some implementations, a sleeve can be placed within the preset mold before pouring the concrete mix. When the concrete mix dries, the concrete layer includes a cavity through which a plumbing pipe can run. A similar approach can also be used for outdoor hoses.